U.S. patent number 10,784,059 [Application Number 16/710,713] was granted by the patent office on 2020-09-22 for control circuits for self-powered switches and related methods of operation.
This patent grant is currently assigned to Eaton Intelligent Power Limited. The grantee listed for this patent is Eaton Intelligent Power Limited. Invention is credited to Darron Kirby Lacey, Tom Xiong, Andrew Yang, George Zhang, Harry Zhang, Alex Zhuang.
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United States Patent |
10,784,059 |
Zhang , et al. |
September 22, 2020 |
Control circuits for self-powered switches and related methods of
operation
Abstract
Self-powered switches include a switch housing having an
externally accessible user input member, a coil assembly, and a
magnet arranged therein such that at least one of the coil assembly
and the magnet move relative to each other responsive to movement
of the user input member between first and second switch positions,
and a control circuit held in the switch housing and coupled to
first and second terminals of the coil assembly. The control
circuit is configured to detect respective electrical
characteristics of the first and second terminals of the coil
assembly responsive to the movement of the user input member, and
selectively transmit first and second wireless control signals to a
remote receiver based on the respective electrical characteristics
of the first and second terminals of the coil assembly,
respectively. Related circuits and methods of operation are also
discussed.
Inventors: |
Zhang; Harry (Shanghai,
CN), Yang; Andrew (Jiangsu, CN), Zhuang;
Alex (Shanghai, CN), Zhang; George (Shanghai,
CN), Xiong; Tom (Shanghai, CN), Lacey;
Darron Kirby (Peachtree City, GA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Eaton Intelligent Power Limited |
Dublin |
N/A |
IE |
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Assignee: |
Eaton Intelligent Power Limited
(Dublin, IE)
|
Family
ID: |
1000005070633 |
Appl.
No.: |
16/710,713 |
Filed: |
December 11, 2019 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20200118772 A1 |
Apr 16, 2020 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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15427951 |
Feb 8, 2017 |
10541093 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01H
9/168 (20130101); H01H 23/143 (20130101); H01H
2239/076 (20130101); H01H 2300/03 (20130101); H01H
2239/078 (20130101) |
Current International
Class: |
H01H
9/16 (20060101); H01H 23/14 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Leviton "No Wires, No Batteries, No Limits: Wireless Sensing
Solution" Product Brochure (7 pages) (2008). cited by applicant
.
Leviton "Self-Powered Lighting Control Solutions by LevNet RF"
Product Brochure (2 pages) (2010). cited by applicant .
Leviton "Self-Powered Wireless Controls" www.leviton.com (3 pages)
(date unknown; printed from the internet Jan. 13, 2017). cited by
applicant.
|
Primary Examiner: Fureman; Jared
Assistant Examiner: Barnett; Joel
Attorney, Agent or Firm: Myers Bigel, P.A.
Parent Case Text
RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No.
15/427,951, filed Feb. 8, 2017, the contents of which are hereby
incorporated by reference as if recited in full herein.
Claims
That which is claimed is:
1. A control circuit for a self-powered switch comprising a coil
assembly and a magnet configured to move relative to each other
responsive to movement of a user input member, the control circuit
comprising: a transmitter circuit configured for wireless
communication with a remote receiver; a phase detection circuit
configured to be coupled to first and second terminals of the coil
assembly and configured to generate first and second output signals
responsive to movement of the user input member to first and second
switch positions, respectively; and a processor coupled to the
phase detection circuit and the transmitter circuit, wherein the
processor is configured to detect respective electrical
characteristics of the first and second terminals of the coil
assembly based on the first and second output signals from the
phase detection circuit, respectively, and is configured to operate
the transmitter circuit to selectively transmit first and second
wireless control signals to the remote receiver based on the
respective electrical characteristics of the first and second
terminals of the coil assembly, respectively.
2. The control circuit of claim 1, wherein the respective
electrical characteristics comprise first and second voltage states
of the first and second terminals of the coil assembly responsive
to the movement of the user input member to the first and second
switch positions, respectively, wherein the processor is configured
to operate the transmitter circuit to transmit the first wireless
control signal to the remote receiver for connecting a load thereof
to a power source in response to detection of the first voltage
state at the first terminal, and transmit the second wireless
control signal to the remote receiver for disconnecting the load
from the power source in response to detection of the second
voltage state at the second terminal.
3. The control circuit of claim 1, wherein the phase detection
circuit comprises: a first circuit comprising a first capacitor
coupled to the first terminal of the coil assembly and configured
to generate the first output signal based on a first voltage state
of the first capacitor responsive to the movement of the user input
member to the first switch position; and a second circuit
comprising a second capacitor coupled to the second terminal of the
coil assembly and configured to generate the second output signal
based on a second voltage state of the second capacitor responsive
to the movement of the user input member to the second switch
position.
4. The control circuit of claim 3, wherein the phase detection
circuit further comprises: a first regulator coupled to the first
capacitor and configured to regulate the first output signal to
below a predetermined voltage; and a second regulator coupled to
the second capacitor and configured to regulate the second output
signal to below the predetermined voltage.
5. The control circuit of claim 1, further comprising: an energy
harvesting circuit coupled to the first and second terminals of the
coil assembly and comprising at least one capacitor that is
configured to store a voltage sufficient to operate the transmitter
circuit for wireless communication with the remote receiver
responsive to the movement of the user input member to each of the
first and second switch positions.
6. The control circuit of claim 1, further comprising: a circuit
board including the transmitter circuit, the phase detection
circuit, and/or the processor thereon, wherein the circuit board
includes first and second input terminals configured to be attached
to the first and second terminals of the coil assembly, and wherein
the first and second terminals of the coil assembly comprise
opposite ends of a wire coil.
7. The control circuit of claim 6, wherein the phase detection
circuit is configured to be coupled to the first and second
terminals of the coil assembly comprising the opposite ends of the
wire coil, wherein the wire coil is wound about a shaft that
extends beyond the wire coil and towards the magnet of the
self-powered switch.
8. The control circuit of claim 6, wherein the first and second
input terminals of the circuit board are configured to be attached
to the first and second terminals of the coil assembly,
respectively, through at least one coil terminal aperture of a
switch housing of the self-powered switch.
9. The control circuit of claim 1, wherein the remote receiver is
held in a remote receiver housing that is distinct from a switch
housing of the self-powered switch and comprises at least one relay
therein that is configured to be connected to a power source.
10. The control circuit of claim 9, wherein the transmitter circuit
is configured to communicate with a receiving circuit held in the
remote receiver housing and coupled to the at least one relay,
wherein the receiving circuit is configured to receive the first
and second wireless control signals from the control circuit and
operate the at least one relay to connect and disconnect a load
thereof to and from the power source responsive to the first and
second wireless control signals, respectively.
Description
FIELD
The present invention relates to electrical switches.
BACKGROUND
Conventional switches that control a variety of electrical devices
may require hard-wired connections to a power source, including
associated external wiring, power cords, etc., connected between
the switch and a load. For example, a wall-mounted switch may be
electrically connected to a light source via an electrical wire for
controlling the light source in an on-and-off manner. The wiring
configuration is typically pre-designed in a floor plan of the
building to illustrate the exact location of the controlling switch
to run the electrical wire from the illuminator to the controlling
switch. In addition, a switch box, PVC wire sleeve, and electric
wires may be embedded into the wall, which may require damage to
the wall in order to re-locate the switch.
Wireless switches, which may transmit a wireless signal to control
electrical devices, may address some of the above issues. However,
wireless electronic switches typically require an internal battery
having a limited lifetime. As such, the battery must be replaced
after a period of time, which may be inconvenient for user.
SUMMARY
Some embodiments of the present invention are directed to
micro-control circuits for self-powered switches that can be used
to wirelessly control electrical devices without requiring battery
power or a wired connection to an external power source.
According to some embodiments, a self-powered switch includes a
switch housing comprising an externally accessible user input
member, a coil assembly, and a permanent magnet arranged therein
such that at least one of the coil assembly and the permanent
magnet move relative to each other responsive to movement of the
user input member between first and second switch positions, and a
control circuit held in the switch housing and coupled to first and
second terminals of the coil assembly. The control circuit is
configured to detect respective electrical characteristics of the
first and second terminals of the coil assembly responsive to the
movement of the user input member, and selectively transmit first
and second wireless control signals to a remote receiver based on
the respective electrical characteristics of the first and second
terminals of the coil assembly, respectively.
In some embodiments, the respective electrical characteristics may
include first and second voltage states of the first and second
terminals of the coil assembly responsive to the movement of the
user input member to the first and second switch positions,
respectively. The control circuit may be configured to transmit the
first wireless control signal in response to detection of the first
voltage state at the first terminal, and transmit the second
wireless control signal in response to detection of the second
voltage state at the second terminal.
In some embodiments, the control circuit may include a transmitter
circuit configured for wireless communication with the remote
receiver, a phase detection circuit coupled to the first and second
terminals of the coil assembly and configured to generate first and
second output signals responsive to the movement of the user input
member to the first and second switch positions, respectively, and
a processor coupled to the phase detection circuit and the
transmitter circuit. The processor may be configured to detect the
respective electrical characteristics of the first and second
terminals of the coil assembly based on the first and second output
signals from the phase detection circuit, respectively. The
processor may be configured to operate the transmitter circuit to
transmit the first wireless control signal to the remote receiver
for connecting a load thereof to a power source responsive to the
first output signal, and to transmit the second wireless control
signal to the remote receiver for disconnecting the load from the
power source responsive to the second output signal.
In some embodiments, the phase detection circuit may include a
first circuit including a first capacitor coupled to the first
terminal of the coil assembly and configured to generate the first
output signal based on a first voltage state of the first capacitor
responsive to the movement of the user input member to the first
switch position, and a second circuit including a second capacitor
coupled to the second terminal of the coil assembly and configured
to generate the second output signal based on a second voltage
state of the second capacitor responsive to the movement of the
user input member to the second switch position.
In some embodiments, the control circuit may further include an
energy harvesting circuit coupled to the first and second terminals
of the coil assembly. The energy harvesting circuit may include at
least one capacitor that is configured to store a voltage
sufficient to operate the transmitter circuit for wireless
communication with the remote receiver responsive to the movement
of the user input member to each of the first and second switch
positions.
In some embodiments, the coil assembly may include a wire coil
wound about a shaft that extends beyond the wire coil and towards
the permanent magnet, where the first and second terminals may
define opposite ends of the wire coil.
In some embodiments, the permanent magnet may be held between
spaced apart first and second plates in the switch housing that
extend beyond the permanent magnet and toward the coil assembly to
define a cavity between inner surfaces thereof. An end of the shaft
may extend into the cavity and may pivot to contact the inner
surfaces of the first and second plates in response to movement of
the user input member to the first and second switch positions,
respectively.
In some embodiments, the switch may include at least one circuit
board including the control circuit thereon in the switch housing,
and a top member and a bottom member in the switch housing with the
coil assembly held therebetween. The top member may include at
least one coil terminal aperture through which the first and second
terminals of the coil assembly may extend to contact input
terminals of the circuit board.
In some embodiments, the switch may include a remote receiver
housing that is distinct from the switch housing. The remote
receiver housing may include at least one relay therein that is
configured to be connected to a power source, and a receiving
circuit held in the remote receiver housing and coupled to the at
least one relay. The receiving circuit may be configured to receive
the first and second wireless control signals from the control
circuit and operate the at least one relay to connect and
disconnect a load thereof to and from the power source responsive
to the first and second wireless control signals, respectively.
According to some embodiments, a control circuit is provided for a
self-powered switch that includes a coil assembly and a magnet
configured to move relative to each other responsive to movement of
a user input member. The control circuit includes a transmitter
circuit configured for wireless communication with a remote
receiver, a phase detection circuit coupled to first and second
terminals of the coil assembly and configured to generate first and
second output signals responsive to movement of the user input
member to first and second switch positions, respectively, and a
processor coupled to the phase detection circuit and the
transmitter circuit. The processor is configured to detect
respective electrical characteristics of the first and second
terminals of the coil assembly based on the first and second output
signals from the phase detection circuit, respectively, and operate
the transmitter circuit to selectively transmit first and second
wireless control signals to the remote receiver based on the
respective electrical characteristics of the first and second
terminals of the coil assembly, respectively.
In some embodiments, the respective electrical characteristics may
be first and second voltage states of the first and second
terminals of the coil assembly, where the first and second voltage
states are responsive to the movement of the user input member to
the first and second switch positions, respectively. The processor
may be configured to operate the transmitter circuit to transmit
the first wireless control signal to the remote receiver for
connecting a load thereof to a power source in response to
detection of the first voltage state at the first terminal, and
transmit the second wireless control signal to the remote receiver
for disconnecting the load from the power source in response to
detection of the second voltage state at the second terminal.
In some embodiments, the phase detection circuit may include a
first circuit including a first capacitor coupled to the first
terminal of the coil assembly and configured to generate the first
output signal based on a first voltage state of the first capacitor
responsive to the movement of the user input member to the first
switch position, and a second circuit including a second capacitor
coupled to the second terminal of the coil assembly and configured
to generate the second output signal based on a second voltage
state of the second capacitor responsive to the movement of the
user input member to the second switch position.
In some embodiments, the control circuit may further include an
energy harvesting circuit coupled to the first and second terminals
of the coil assembly. The energy harvesting circuit may include at
least one capacitor that is configured to store a voltage
sufficient to operate the transmitter circuit for wireless
communication with the remote receiver responsive to the movement
of the user input member to each of the first and second switch
positions.
In some embodiments, the control circuit may further include a
circuit board including the transmitter circuit, the phase
detection circuit, and/or the processor thereon. The circuit board
may include first and second input terminals attached to the first
and second terminals of the coil assembly. The first and second
terminals may define opposite ends of a wire coil of the coil
assembly.
According to some embodiments, a method is provided for operating a
control circuit for a self-powered switch that includes a coil
assembly and a magnet configured to move relative to each other
responsive to movement of a user input member. The method includes
detecting, by a processor, respective electrical characteristics of
first and second terminals of the coil assembly responsive to the
movement of the user input member, and selectively transmitting,
via a transmitter circuit coupled to the processor, first and
second wireless control signals to a remote receiver based on the
respective electrical characteristics of the first and second
terminals of the coil assembly, respectively.
In some embodiments, the respective electrical characteristics may
be first and second voltage states of the first and second
terminals of the coil assembly responsive to the movement of the
user input member to first and second switch positions,
respectively. Selectively transmitting the first and second
wireless control signals may include transmitting, via the
transmitter circuit coupled to the processor, the first wireless
control signal in response to detection of the first voltage state
at the first terminal, and transmitting, via the transmitter
circuit coupled to the processor, the second wireless control
signal in response to detection of the second voltage state at the
second terminal.
In some embodiments, detecting the respective electrical
characteristics of the first and second terminals of the coil
assembly may include receiving, from a phase detection circuit
coupled to the processor, first and second output signals
responsive to the movement of the user input member to the first
and second switch positions, respectively, and detecting, by the
processor, the respective electrical characteristics of the first
and second terminals of the coil assembly based on the first and
second output signals from the phase detection circuit,
respectively. Selectively transmitting the first and second
wireless control signals may include transmitting, via the
transmitter circuit coupled to the processor, the first wireless
control signal to the remote receiver for connecting a load thereof
to a power source responsive to the first output signal, and
transmitting, via the transmitter circuit coupled to the processor,
the second wireless control signal to the remote receiver for
disconnecting the load from the power source responsive to the
second output signal.
In some embodiments, the method may further include generating, by
the phase detection circuit, the first output signal based on a
first voltage state of a first capacitor that is coupled to the
first terminal of the coil assembly responsive to the movement of
the user input member to the first switch position, and generating,
by the phase detection circuit, the second output signal based on a
second voltage state of the second capacitor coupled to the second
terminal of the coil assembly responsive to the movement of the
user input member to the second switch position.
In some embodiments, the method may further include storing, in at
least one capacitor of an energy harvesting circuit coupled to the
first and second terminals of the coil assembly, a voltage
sufficient to operate the transmitter circuit for wireless
communication with the remote receiver responsive to the movement
of the user input member to each of the first and second switch
positions.
Further features, advantages and details of the present invention
will be appreciated by those of ordinary skill in the art from a
reading of the figures and the detailed description of the
preferred embodiments that follow, such description being merely
illustrative of the present invention.
It is noted that aspects of the invention described with respect to
one embodiment, may be incorporated in a different embodiment
although not specifically described relative thereto. That is, all
embodiments and/or features of any embodiment can be combined in
any way and/or combination. Applicant reserves the right to change
any originally filed claim or file any new claim accordingly,
including the right to be able to amend any originally filed claim
to depend from and/or incorporate any feature of any other claim
although not originally claimed in that manner. These and other
objects and/or aspects of the present invention are explained in
detail in the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front, side perspective view of an exemplary
self-powered switch assembly according to embodiments of the
present invention.
FIG. 2 is side, bottom perspective view of the switch shown in FIG.
1.
FIG. 3A is a side perspective partially exploded view of the
exemplary switch shown in FIG. 1.
FIG. 3B is another side perspective partially exploded view of the
exemplary switch shown in FIG. 1.
FIG. 4A is a side, section assembled view of the device shown in
FIG. 1 according to embodiments of the present invention.
FIG. 4B is a side, section assembled view of the device shown in
FIG. 1 with the shaft pivoted to alter magnetic field lines
according to embodiments of the present invention.
FIG. 5A is a top, partially exploded view of the device shown in
FIG. 1.
FIG. 5B is a side partially exploded view of a toggle and housing
sub-assembly for the switch shown in FIG. 5A according to
embodiments of the present invention.
FIG. 5C is a partial assembly view of the sub-assembly shown in
FIG. 5B.
FIG. 5D is a side perspective assembled view of the sub-assembly
shown in FIG. 5B.
FIG. 5E is a bottom perspective assembled view of the toggle and
housing sub-assembly shown in FIG. 5B.
FIGS. 6A and 6B are enlarged schematic illustrations of different
positions of the coil and permanent magnet for a self-powered
switch according to embodiments of the present invention.
FIG. 7A is a side partially exploded view of internal components of
the switch shown in FIG. 1 according to embodiments of the present
invention.
FIG. 7B is a side perspective assembled view of the internal
components shown in FIG. 7A.
FIG. 8A is a side perspective exploded view of a receiver that
wirelessly communicates with the self-powered switch according to
embodiments of the present invention.
FIG. 8B is a side perspective assembled view of the receiver shown
in FIG. 8A according to embodiments of the present invention.
FIG. 9 is a schematic illustration of an in-wall mounted
self-powered light switch and a light with a receiver according to
embodiments of the present invention.
FIGS. 10-16 are circuit diagrams illustrating transmission/control
and receiving circuits according to embodiments of the present
invention.
FIG. 10 is a schematic illustration of a control circuit of a
self-powered switch according to embodiments of the present
invention.
FIG. 11 is a schematic illustration of a receiving circuit of the
remote receiver according to embodiments of the present
invention.
FIG. 12 is an example of an energy harvesting unit for the control
circuit of FIG. 10.
FIG. 13 is an example of a DC power unit for the control circuit of
FIG. 10.
FIG. 14 is an example of a phase detection unit for the control
circuit of FIG. 10.
FIG. 15 is an example AC-DC power unit of the receiving circuit of
FIG. 11.
FIG. 16 is an example of a relay control unit of the receiving
circuit of FIG. 11.
FIG. 17 is a side perspective view of an alternate embodiment of a
self-powered switch according to embodiments of the present
invention.
DETAILED DESCRIPTION OF EMBODIMENTS
The present invention now will be described more fully hereinafter
with reference to the accompanying drawings, in which illustrative
embodiments of the invention are shown. Like numbers refer to like
elements and different embodiments of like elements can be
designated using a different number of superscript indicator
apostrophes (e.g., 10, 10', 10'', 10'''). Abbreviated versions of
the word "Figure" such as "FIG." and "Fig." are used
interchangeably in the application. Broken line boxes in the
figures indicate optional features.
In the drawings, the relative sizes of regions or features may be
exaggerated for clarity. This invention may, however, be embodied
in many different forms and should not be construed as limited to
the embodiments set forth herein; rather, these embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the invention to those skilled in
the art.
It will be understood that, although the terms first, second, etc.
may be used herein to describe various elements, components,
regions, layers and/or sections, these elements, components,
regions, layers and/or sections should not be limited by these
terms. These terms are only used to distinguish one element,
component, region, layer or section from another region, layer or
section. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the present invention.
Spatially relative terms, such as "beneath", "below", "lower",
"above", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if the device in the figures is turned over, elements
described as "below" or "beneath" other elements or features would
then be oriented "above" the other elements or features. Thus, the
exemplary term "below" can encompass both an orientation of above
and below. The device may be otherwise oriented (rotated 90.degree.
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly.
The term "about" refers to numbers in a range of +1-20% of the
noted value.
As used herein, the singular forms "a", "an" and "the" are intended
to include the plural forms as well, unless expressly stated
otherwise. It will be further understood that the terms "includes,"
"comprises," "including" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. It
will be understood that when an element is referred to as being
"connected" or "coupled" to another element, it can be directly
connected or coupled to the other element or intervening elements
may be present. Elements "connected" or "coupled" to one another
may refer to physical and/or electrical connections or couplings
between the elements. As used herein, the term "and/or" includes
any and all combinations of one or more of the associated listed
items.
Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of this specification and the relevant art
and will not be interpreted in an idealized or overly formal sense
unless expressly so defined herein.
Turning now to the figures, FIG. 1 and FIG. 2 illustrate an
exemplary self-powered switch 10. The switch 10 can be a switch
that controls electrical devices such as ON and OFF controls for
appliances, televisions, lights, garage door openers and the like.
The switch 10 can wirelessly control the electrical device,
typically a remote electrical device.
The switch 10 can have an externally accessible user input member
15, shown as a paddle push button (also known as a "toggle") with
first and second end portions that rock between different, i.e., on
and off, positions (shown by the arrow in FIG. 4A, for
example).
The switch 10 can be configured, for example, as an in-floor
device, in-wall device, surface-mount device, or a device
integrated into another device or even as an OFF/ON control for an
appliance. As shown in FIGS. 1 and 2, the switch 10 has a housing
20, and at least one mounting bracket 16, shown as two mounting
brackets, one extending off each end portion, that can engage one
or more fixation members 18 such as screws to mount to a target
structure, and an optional strap 24 which may be metal and/or a
ground strap. The embodiment shown in FIG. 1 and FIG. 2 may be
particularly suitable as an in-wall, optionally flush-mount surface
switch that can wirelessly control a remote electrical appliance or
device, such as a light 240 via a remote receiver 200 (FIGS. 8A, 8B
and 9).
Referring to FIGS. 3A, 3B, 4A and 4B, the housing 20 can include a
bottom housing 21 and a cooperating mid-housing 22 that are
attached together. The mid-housing 22 can reside between the user
input member 15 and the bottom housing 21. The switch 10 also
includes an electromagnetic coil assembly 50 with an internal
housing 50h residing under the user input member 15 and holding a
wire coil (also referred to herein as a coil) 52 and a core or
shaft 55 extending through the wire coil 52. The wire coil 52 is
wound about the shaft 55 (either directly wound around the shaft,
or, more typically, wound about a separate member, as shown in FIG.
7A). The end portion of the shaft 55e can extend into a cavity 160
to face a permanent magnet 60 held in the bottom housing 21. The
permanent magnet 60 can be held in a cradle 30 in the bottom
housing 21. The user input member 15 can include inwardly extending
brackets 33 that attach to the housing 50h. The brackets 33 can
comprise a plurality of longitudinally spaced apart brackets 33
that extend from each long side of the user input member 15. The
brackets 33 can frictionally engage the housing 50h.
Referring to FIGS. 3A, 3B, 4A, 4B and 5A, the mid-housing 22 can
include inwardly extending brackets 40 that attach to the bottom
housing 21. The brackets 40 can extend from ends (short sides) of
the mid-housing 22. The brackets 40 can include outwardly extending
protrusions 40p that can engage a window 16w in the strap 23 of the
mounting bracket 16. The mounting bracket 16 can be metal. The
housing 20 may be polymeric or metal.
The shaft 55 can be a ferromagnetic (i.e., steel) shaft of any
suitable shape. As shown in FIG. 7A, the shaft 55 is a planar plate
which can have a polygonal shape, typically having a pair of long
sides and a pair of short sides with one of the short sides
providing the end 55e that faces the permanent magnet 60.
Still referring to FIG. 7A, the coil 52 can include a pair of long
sides 52l joined by a pair of short sides 52s and can have a number
of adjacent, stacked coil turns N, where N is typically between 10
and 10,000. The coil 52 can have an open center channel 52c (FIG.
5E) surrounded by the long and short sides 52l, 52s that the shaft
55 extends through. In particular embodiments, the long sides have
a length that is between 2.times.-4.times. greater than the length
of the short sides.
The permanent magnet 60 can comprise a rare earth magnet, such as,
for example, a neodymium magnet (also known as a NdFeB magnet),
made from an allow of neodymium, iron and boron. Particular
examples of rare earth magnets that may be suitable for the
permanent magnet 60 include Nd.sub.2Fe.sub.14B, SmCo.sub.5 and
Sm(Co,Fe,Cu,Zr).sub.7. As shown in FIG. 7A, the permanent magnet 60
can have a rectangular shape with a long side facing the shaft end
55e and extending laterally across the housing 20.
As shown in FIGS. 3B, 4A, 4B, and 5A-5E, for example, the housing
50h can be attached to the user input member 15. The housing 50h
can include a laterally outwardly extending spindle 17 that resides
in opposing side channels 170 of the housing 20. The spindle 17 can
comprise first and second spindle segments (rather than a
continuous length member) and can extend outward under opposing
long sides of the user input member 15 to pivotably engage the
channels 170.
The side channels 170 in the switch housing 20 can be bearing
channels for the spindle 17. The side channels 170 can be formed by
cooperating pairs of arcuate channels that face each other 170a,
170b in the mid housing 22 and the bottom housing 21,
respectively.
FIGS. 3B and 5A-5E show that the user input member 15 may include
laterally extending shaft segments 14 that reside adjacent the
spindle 17 and which can extend laterally outward a shorter
distance than the spindle 17. The shaft segments 14 and spindle
segments can each reside in a common channel portion of the switch
housing, i.e., within pairs of the cooperating channels 170a,
170b.
Referring to FIGS. 4A, 4B, 5B, 5C, 7A, and 7B, the switch 10 can
also include at least one circuit board 150, which may comprise a
flexible and/or a rigid printed circuit board. The at least one
circuit board 150 can include power connections 153 to extensions
59 (defining first and second coil terminals 59) of the coil 52 and
can hold a transmitter 260 and a power-generation harvesting
circuit 270 (FIG. 7A). The at least one circuit board 150 can
reside under the user input member 15, typically in a cavity 75
above the shaft 55 (in the orientation shown in FIGS. 3A, 4A and
4B, for example). The cavity 75 can be provided between a planar
portion of the magnet coil housing 50h adjacent and under the user
input member 15.
Referring to FIGS. 4A, 4B, 6A, and 6B, the housing 50h can pivot
about the spindle 17 as a unit with the user input member 15 to
move the end of the shaft 55e side to side in a cavity 160 above
the permanent magnet 60. The pivoting action causes the centerline
of the shaft to change in angular orientation an angular distance
.theta. that can be between 10-40 degrees, typically 10-30 degrees,
to pivot the end of the shaft 55e to contact opposing inner
surfaces of plates 62 which extend a short distance above the
permanent magnet 60. The plates 62 can be ferromagnetic, i.e.,
steel, conductive plates 62 and can alter flux lines between the
coil 52 and the N, S poles of the permanent magnet 60 as shown in
FIG. 6A, 6B. The magnetic pole orientation can be provided in the
reverse from that shown. The plates 62 can have other shapes and
are not required to be planar.
FIGS. 7A and 7B illustrate exemplary embodiments of the coil
assembly 50 and the permanent magnet 60 with cooperating components
such as the plates 62 and thinner, shorter shim plates 64 that can
be used to adjust the distance of the N-S poles from the end of the
shaft 55e.
The permanent magnet 60 can be rectangular with a pair of long
sides joined by a pair of short sides and, as shown in FIG. 7A, the
long sides can extend in a lateral dimension of the switch housing
across between 50-100% of a lateral extent L of the switch housing
20, more typically between 75-100% of the lateral extent.
Referring to FIGS. 5B, 7A, and 7B, the at least one circuit board
150 can comprise the power inputs 153 that connect to the
terminals/extensions 59 of the coil 52. The coil 52 can be held
between longitudinally spaced apart first and second end members
56, 57 that have channels 56c, 57c through which the shaft 55
extends. The first end member 56 can also include at least one
aperture 56a that the terminals 59 can be routed through to attach
to the power inputs/connections 153 on the at least one circuit
board 150. The channel 56c of the first member 56 can frictionally
engage the top end portion of the shaft 55t facing the user input
member 15. However, other attachment configurations may be used.
The coil assembly 50 can also include a magnet yoke 58, shown as
comprising first and second yoke members 58.sub.1, 58.sub.2 that
attach to the first and second end members 56, 57 (FIGS. 7A, 7B).
The coil assembly 50 can be held in the housing 50h (FIGS. 4A, 4B,
5A-5E) as discussed above.
The at least one circuit board 150 can comprise a rectangular shape
as shown in FIGS. 5B, 7A, and 7B. The user input member 15 can have
at least a portion that is visually transmissive, such as
transparent or translucent. The entire user input member 15 can be
visually transmissive and the at least one circuit board 150 can be
visually seen by a user. In some particular embodiments, the at
least one circuit board 150 can be a single circuit board.
As shown in FIG. 5B-5E, in some embodiments the switch 10 includes
a toggle and housing sub-assembly 15a. The terminals 59 of the coil
52 can be attached to the at least one printed circuit board 150.
This package 50p (FIG. 5B) can be inserted into the housing 50h
with the printed circuit board 150 in the cavity 75 (FIG. 5C). The
user input member 15 can then be press-fit attached to the housing
50h (FIG. 5D, 5E) to form the sub-assembly 15a.
The housing 50h can comprise curvilinear ends 190 (which may be
shaped as semicircular ears) that engage the attachment members 33
of the user input member 15.
As shown in FIG. 7A, the at least one circuit board 150 can include
a transmitter 260 and a power generator harvesting circuit 270.
As shown in FIG. 17, it is also contemplated that the permanent
magnet 60 and plates 62 can be held by the magnet housing 50h and
move (based on the spindle attachment to the housing 20) relative
to the coil 52 and shaft 55, which can be stationary. The coil 52
can be held in the bottom housing 22 aligned with a medial portion
of the user input member 15 under the magnet 60. The at least one
printed circuit board 150, can reside under the coil 52 and
terminals 59 can extend longitudinally outward or below the coil
52. The transmitter 260 can reside closer to the user input member
15 than the coil 52.
FIGS. 8A and 8B illustrate an exemplary remote receiver 200 that
can be wirelessly operated by the switch 10. The receiver 200 can
include a base 201, a cover 202, an indicator light 206 and a
switch match code member 210. The indicator light 206 can reflect
active or inactive status based on the ON or OFF configuration of
the switch 10, for example. The switch match code member 210 can be
configured to recognize signal from a particular switch or the
switch can be coded to work with only corresponding receivers 200
having a match where more than one switch 10, or a different toggle
15, of a single switch 10, may be used for different purposes
and/or different lights, for example.
FIG. 9 illustrates one exemplary application of the switch 10 in a
commercial or residential building as a switch 10 that wirelessly
directs the receiver 200 to turn the light 240 ON and OFF, for
example, by transmitting first and second control signals 220a,
220b in response to actuation of the user input member 15 to first
and second switch positions, respectively.
FIG. 10 is a schematic illustration of an example control circuit
400 of the self-powered switch 10. The control circuit 400 may be
included in the switch housing 20, and is configured to output
control signals 220a, 220b (FIG. 9) that operate the remote
receiver 200 to connect or disconnect an electrical appliance or
other device coupled thereto to or from a power source, such as an
AC power source. The control circuit 400 includes an energy
harvesting unit 270, a DC power unit 325, a phase detection unit
350, an MCU unit (processor unit) 360, and a transmission unit 370.
For clarity, it is noted that the term "unit" when referring to the
circuit structures of FIGS. 10-16, for example, is used for ease of
discussion to refer to circuits or sub-circuits and may be
distributed or held on a single component, i.e., substrate or
printed circuit board and which may share components of other units
(circuits or sub-circuits).
FIG. 11 is a schematic illustration of a receiving circuit 500 of
the remote receiver 200. The receiving circuit 500 can include an
AC power supply unit 505, an AC-DC power unit 510, a configuration
unit 512, an MCU (or processor) unit 515, a receiver unit 518, and
a relay control unit 520. The AC-DC power unit 510 converts the
input AC power into DC power, the configuration unit 512 controls
switching of the receiving circuit 500 into a pairing mode for
receiving wireless control signals from the control circuit 400 via
the receiving unit 518, and the processor unit 515 analyzes the
wireless control signal provided by the receiving unit 518 and
controls action of the relay control unit 520 in response to the
wireless control signal.
FIG. 12 is an example of an energy harvesting unit 270 for the
control circuit 400 (FIG. 10). The energy harvesting unit 270 is
configured to gather electromagnetic energy and convert the
electromagnetic energy into electrical energy, in particular,
electromotive force. In the example of FIG. 12, the energy
harvesting unit 270 includes at least one power storage capacitor
300, power inputs 153 (P+ and P- coupled to the first and second
terminals of the coil 52, respectively), and a rectifier bridge
D1,D2 coupled to the first and second terminals 59 of the coil 52.
Alternating current, which is induced by movement of the coil 52
and/or magnet 60 relative to one another due to actuation of the
user input member 15, is provided to one of the inputs 153 via the
terminals of the coil 52 (depending on the position of the user
input member 15), is rectified by the rectifier bridge D1, D2, and
charges the capacitor 300. The voltage across the capacitor 300 can
be stabilized at 12V by regulator D6, and is sufficient to operate
one or more other components of the control circuit 400. For
example, in some embodiments, the movement of the coil 52 and/or
magnet 60 relative to one another due to actuation of the user
input member 15 may be sufficient to generate a voltage of about 5V
DC for about 4 ms, as measured at the capacitor 300.
FIG. 13 is an example of a DC power unit 325 for the control
circuit 400 (FIG. 10). The DC power unit 325 is used to generate a
desired DC voltage from the 12V provided by the energy harvesting
unit 270, for example, to operate one or more other components of
the control circuit 400. In the example of FIG. 13, the DC power
unit 325 generates a +3.3V DC power source, which is suitable for
providing operating power for the transmitter unit 370; however, it
will be understood that other voltages may be generated based on
the design of the control circuit 400.
FIG. 14 is an example of a phase detection unit 350 for the control
circuit 400 (FIG. 10). The phase detection unit 350 is coupled to
the first and second terminals 153 (P+ and P-) of the wire coil 52,
and is configured to detect a direction of current or power
resulting from actuation of the user input member 15. In the
example of FIG. 14, the phase detection unit 350 includes a "close
control" circuit 351 and an "open control" circuit 352. The P+
connection 153 of the close control circuit 351 is connected to one
of the two terminals 59 of the wire coil 52, while the P-
connection 153 of the open control circuit 352 is connected to the
other of the two terminals of the wire coil 52. Alternating
current, which is induced by movement of the coil 52 and/or magnet
60 relative to one another, is provided to one of the inputs 153
via the terminals of the coil 52 (depending on the position of the
user input member 15), and charges the capacitor C4 or C8, which
provides an output "Close_ctrl" or "Open_ctrl" (regulated to below
3.3V by regulators D4 or D7) to the processor 360. That is, the
current induced by the movement of the coil 52 and/or magnet 60
relative to one another is used not only by the energy harvesting
unit 270 to charge the storage capacitor 300, but can be separately
used by the phase detection unit 350 to generate outputs that are
indicative of the respective voltage states of the terminals 59 of
the coil 52 responsive to movement of the user input member 15 to
(or from) the first and second switch position, respectively. As
described in greater detail below, the outputs of the phase
detection unit 350 are used by the processor 360 to selectively
control the transmitter unit 370 to transmit a first wireless
control signal 220a (FIG. 9) to the remote receiver 200 to connect
a load 240 thereof to the power source in response to detection of
one of the voltage states, and to transmit a second wireless
control signal 220b (FIG. 9) to the remote receiver 200 to
disconnect the load 240 from the power source in response to
detection of the other of the voltage states. More generally,
respective electrical characteristics of the terminals 59 of the
coil 52 (resulting from movement of the user input member 15 to the
first and second switch positions) are used to control transmission
of the wireless control signals 220a, 220b to the remote receiver
200.
FIG. 15 is an example AC-DC power unit 510 of the receiving circuit
500 (FIG. 11). The AC-DC power unit 510 converts the AC power from
the AC power supply unit 505 into DC power for operating one or
more other components of the control circuit 400. In the example of
FIG. 15, the AC-DC power unit 510 generates a 12V DC source to
power the relay control unit (FIG. 16), as well as a 3.3V DC power
source to power the receiver unit 518. However, it will be
understood that other voltages may be generated based on the design
of the receiving circuit 500.
FIG. 16 is an example of a relay control unit 520 of the receiving
circuit 500 (FIG. 11). The relay control unit 520 is configured to
control operation of a relay to connect or disconnect a load (e.g.,
an electronic appliance or other device coupled to the remote
receiver 200) to or from an AC power source. In particular, as
noted above with reference to FIG. 11, in response to receiving a
wireless control signal from the control circuit 400, the processor
unit 515 provides an output "Relay_ctrl" to the relay control unit
520, which controls operation of the relay K11 via triode Q41 to
either close the relay K11 to provide a connection between
"line_output" and "line_input" (thereby connecting the load to AC
power), or to open the relay K11 to open the connection between
line_output" and "line_input" (thereby disconnecting the load from
AC power).
The self-powered switch 10 can provide power based on the movement
of the user input member 15, which, in turn, moves one or both of
the coil 52 and the permanent magnet 60 relative to one another. By
way of example only, the self-generated power can be based on
electromotive forces generated by operation (in response to)
movement of the user input member 15 (to move one or both of the
permanent magnet 60 and/or coil 52 relative to one another) based
on the below theory of operation: u=N*A*(dB/dt) (Equation 1), where
u is the induced electromotive force, N is the number of turns of
the coil (N can be any suitable number, typically between
10-10,000), A is the sectional area, B is the electromagnetic
induction strength, and t is the time.
(1) When movement of the user input member 15 of the self-powered
switch 10 stops, movement of the coil 52 relative to the magnet 60
likewise stops, and the coil's dB/dt is 0, so the induced
electromotive force u is 0.
(2) When the user input member 15 moves, the coil 52 moves, and the
coil's dB/dt changes, so that the induced electromotive force u has
a value, this induced electromotive force u can be used to generate
power (e.g., by passing through the full wave rectifier D1, D2 of
FIG. 12 to generate DC power/energy). At least one storage
capacitor in the switch 10 can store this DC energy (e.g., in
capacitor 300 of FIG. 12). The storage capacitor's DC voltage can
be between 1-10V for between 2 ms-10 ms, typically about 5V for
about 3-4 ms. The coil 52 through power connections 59 to the power
connectors 153 can provide DC voltage of between 1-10V, typically
about 5V, for between 2-10 ms, typically about 4 ms, to provide
stable electronic operation.
As movement (rather than switch position) of the user input member
15 induces the electromotive force u, some embodiments of the
present invention utilize the phase detection circuit 350 to
selectively control transmission of different wireless control
signals to the receiver circuit 500 of the receiver 200, to either
connect or disconnect the load to or from the AC power source,
based on electrical characteristics observed at the terminals 59 of
the wire coil 52. FIG. 14 schematically illustrates a "close
control" circuit 351 and an "open control" circuit 352 of the phase
detection circuit 350. As noted above, the P+ connection 153 of the
close control circuit 351 is connected to one of the two terminals
of the wire coil 52, while the P- connection 153 of the open
control circuit 352 is connected to the other of the two terminals
of the wire coil 52. The close control circuit 351 and open control
circuit 352 of the phase detection circuit 350 thus generate
respective phase detection output signals ("Close_ctrl" and
"Open_ctrl"), which are indicative of the voltage states of the
first and second terminals of the wire coil 52 when the user input
member 15 is in the first and second switch positions,
respectively.
In greater detail, when the user input member 15 is in an ON switch
position, the P+ terminal of the wire coil 52 has a high voltage
state. The close control circuit 351 generates the "Close_ctrl"
signal indicative of the high voltage state at the P+ terminal, and
provides the "Close_ctrl" signal to an I/O pin of the processor
360. The processor 360 detects this high voltage state at the P+
terminal of the wire coil 52, and outputs a signal to the
transmitter circuit 370 to transmit a first wireless control signal
therefrom. Upon receipt of the first wireless control signal at the
receiver 200, the processor 515 operates the relay control circuit
520 to control a relay K11 (FIG. 16) to close "line_output" and
"line_input," thereby connecting the load to the AC power
source.
On the other hand, when the user input member 15 is in an OFF
switch position, the P- terminal of the coil 52 has a high voltage
state. The open control circuit 352 generates the "Open_ctrl"
signal indicative of the high voltage state at the P- terminal, and
provides the "Open_ctrl" signal to an I/O pin of the processor 360.
The processor 360 detects this high voltage state at the P-
terminal of the wire coil 52, and outputs a signal to the
transmitter circuit 370 to transmit a second wireless control
signal therefrom. Upon receipt of the second wireless control
signal at the receiver 200, the processor 515 operates the relay
control circuit 520 to control the relay K11 (FIG. 16) to open
"line_output" and "line_input," thereby disconnecting the load from
the AC power source.
Accordingly, the processor 360 is configured to detect respective
voltage states at first and second terminals of the wire coil 52
responsive to the outputs of the phase detection circuit 350, where
the respective voltage states correspond to the respective switch
positions of the user input member 15. The processor 360 is thus
configured to operate the transmitter circuit 370 to selectively
transmit a wireless control signal 220a (FIG. 9) to the remote
receiver 200 to connect the load to the power source in response to
detection of one of the respective voltage states, but not in
response to detection of the other of the voltage states.
Conversely, the processor 360 is configured to operate the
transmitter circuit 370 to selectively transmit a different
wireless control signal 220b (FIG. 9) to the remote receiver 200 to
disconnect the load from the power source in response to detection
of one of the respective voltage states, but not in response to
detection of the other of the voltage states. That is, the voltage
states of the first and second terminals 59 of the wire coil 52, as
indicated by the output signals from the phase detection circuit
350, can be detected as an indicator of the respective switch
positions.
The switch 10 can be provided as a single switch package or form
factor or may be provided as a dual or triple side-by-side switch
package (not shown). In some embodiments, the switch 10 can be
configured as an in-wall mount single gang, dual gang or other
multiple gang switch body. The permanent magnet 60 and/or coil 52
and shaft 55 can have a range of motion relative to each other that
is sufficient to induce a voltage to power the transmitter for 1-10
ms, typically from 2-5 ms.
The foregoing is illustrative of the present invention and is not
to be construed as limiting thereof. Although a few exemplary
embodiments of this invention have been described, those skilled in
the art will readily appreciate that many modifications are
possible in the exemplary embodiments without materially departing
from the novel teachings and advantages of this invention.
Accordingly, all such modifications are intended to be included
within the scope of this invention. Therefore, it is to be
understood that the foregoing is illustrative of the present
invention and is not to be construed as limited to the specific
embodiments disclosed, and that modifications to the disclosed
embodiments, as well as other embodiments, are intended to be
included within the scope of the invention.
* * * * *
References